Manufacturing assistance system for an additive manufacturing system

Abstract

The present invention relates to a manufacturing assistance system for an additive manufacturing system, an additive manufacturing system comprising such manufacturing assistance system, a method for operating such manufacturing assistance system and a computer program element for such manufacturing assistance system. The manufacturing assistance system comprises a process sensor unit, an imaging sensor unit and a control unit. The process sensor unit is arrangeable at the additive manufacturing system and configured to generate process data during manufacturing an object by the additive manufacturing system. The imaging sensor unit is arrangeable at the additive manufacturing system and configured to generate image data of the object during manufacturing. The control unit is configured to collect the process data generated by the process sensor unit and the image data generated by the imaging sensor unit and to correlate the process data and the image data to determine a current state of the object.

The invention claimed is: 
     
         1 . A manufacturing assistance system for an additive manufacturing system, comprising:
 a process sensor unit arranged at the additive manufacturing system, comprising one or more hardware sensors selected from a position sensor configured to measure the position of a spot of a scanner of the additive manufacturing system, a distance sensor configured to measure a position of a substrate inside a manufacturing chamber of the additive manufacturing system, a contact sensor configured to determine a contact between the substrate and a doctor blade of the additive manufacturing system, and a temperature sensor configured to measure the temperature of cooling water and/or gas inside the manufacturing chamber, wherein the process sensor unit is configured to generate process data from measurements of the one or more hardware sensors during manufacturing of the object by the additive manufacturing system,   an imaging sensor unit, comprising one or more imaging sensors configured to generate image data of an object during manufacturing inside the manufacturing chamber, wherein the one or more imaging sensors are arranged inside or outside of the manufacturing chamber,   an electronic control unit, comprising a computing element, and   an error detection unit, wherein the error detection unit is arranged inside or outside the manufacturing chamber, and is configured to (i) generate error data based on a human error or interference, during manufacture of the object, and (ii) send the error data to the electronic control unit,   wherein the electronic control unit is configured to (i) collect the process data generated by the process sensor unit, the image data generated by the imaging sensor unit, and the error data generated by the error detection unit, (ii) correlate the process data, the image data, and the error data to determine a current state of the object to verify if the object being manufactured meets predefined requirements or has any failure, and (iii) determine a subsequent step to be performed in the additive manufacturing system and execute the determined subsequent step during manufacturing the object.   
     
     
         2 . The manufacturing assistance system according to  claim 1 , further comprising a system monitoring unit, wherein the system monitoring unit is configured to provide current machine data to the electronic control unit, wherein the electronic control unit is configured to correlate the process data, the image data and/or the current machine data to determine a current state of the object. 
     
     
         3 . The manufacturing assistance system according to  claim 1 , further comprising an image computational unit, wherein the image computational unit is configured to provide CAD data of the object during manufacturing to the electronic control unit, wherein the electronic control unit is configured to correlate the process data, the image data, the error data, machine data and/or the CAD data to determine a current state of the object. 
     
     
         4 . The manufacturing assistance system according to  claim 1 , further comprising an analyzing unit, wherein the analyzing unit is configured to provide analysis data of the object manufactured by the additive manufacturing system to the electronic control unit, wherein the electronic control unit is configured to correlate the process data, the image data, the error data, machine data, CAD data and/or the analysis data to determine a current state of the object. 
     
     
         5 . The manufacturing assistance system according to  claim 1 , wherein the imaging sensor unit comprises an off-axis camera. 
     
     
         6 . The manufacturing assistance system according to  claim 1 , further comprising a data storage element configured to store the process data, the image data, the error data, machine data, CAD data and/or analysis data collected by the electronic control unit, wherein the electronic control unit is configured to send and/or receive data to and/or from the data storage element. 
     
     
         7 . The manufacturing assistance system according to  claim 6 , wherein the data storage element is locally arranged and/or a cloud storage element. 
     
     
         8 . The manufacturing assistance system according to  claim 1 , wherein the electronic control unit is configured to compare currently collected process data, image data, error data, machine data, CAD data and/or analysis data with process data, image data, error data, machine data, CAD data and/or analysis data stored in the data storage element to verify the current state of the object manufactured by the additive manufacturing system. 
     
     
         9 . The manufacturing assistance system according to  claim 1 , wherein the electronic control unit is further configured to determine a subsequent step to be performed in the additive manufacturing system, preferably during and/or after completing manufacturing. 
     
     
         10 . The manufacturing assistance system according to  claim 9 , wherein the electronic control unit is further configured to execute the determined subsequent step during manufacturing the object. 
     
     
         11 . The manufacturing assistance system according to  claim 1 , further comprising a human-machine interface configured to show the current state of the object determined by the electronic control unit and receive an input from an operator based thereon. 
     
     
         12 . The manufacturing assistance system according to  claim 1 , further comprising an adjusting unit, wherein the adjusting unit is configured to adjust a process parameter and/or a machine parameter based on the current state of the object. 
     
     
         13 . The manufacturing assistance system according to  claim 12 , wherein the electronic control unit is configured to adjust the process parameter and/or the machine parameter by applying machine learning. 
     
     
         14 . The manufacturing assistance system according to  claim 1 , wherein the electronic control unit is further configured to receive external process data, external image data, external error data, external machine data, external CAD data and/or external analysis data of another manufacturing assistance system, wherein the control unit is configured to compare the external data with currently collected data and/or data stored in the external data storage element. 
     
     
         15 . An additive manufacturing system, comprising:
 at least a manufacturing module and the manufacturing assistance system of  claim 1 ,   wherein the manufacturing module is configured to additively manufacture an object, and   wherein the manufacturing assistance system is integrated in the manufacturing module.   
     
     
         16 . A method for operating a manufacturing assistance system for an additive manufacturing system, the method comprising:
 generating process data, by a process sensor unit, from measurements of one or more hardware sensors of the process sensor unit during manufacturing an object by the additive manufacturing system, wherein the process sensor unit is arranged at the additive manufacturing system and comprises one or more hardware sensors selected from a position sensor configured to measure the position of a spot of a scanner of the additive manufacturing system, a distance sensor configured to measure a position of a substrate inside a manufacturing chamber of the additive manufacturing system, a contact sensor configured to determine a contact between the substrate and a doctor blade of the additive manufacturing system, and a temperature sensor configured to measure the temperature of cooling water and/or gas inside the manufacturing chamber,   generating image data, by an imaging sensor unit, of an object during manufacturing inside the manufacturing chamber by one or more imaging sensors of the imaging sensor unit, wherein the one or more imaging sensors are arranged inside or outside of the manufacturing chamber,   generating error data, by an error detection unit, based on a human error or interference and during manufacture of the object, wherein the error detection unit is arranged inside or outside the manufacturing chamber, and sending the generated error data to an electronic control unit comprising a computing element,   collecting, by the electronic control unit, the process data generated by the process sensor unit, the image data generated by the imaging sensor unit, and the error data generated by the error detection unit,   determining, by the electronic control unit, a current state of the object by correlating the process data, the image data, and the error data to verify if the object being manufactured meets predefined requirements or has any failure, and   determining a subsequent step to be performed in the additive manufacturing system and executing the determined subsequent step during manufacturing the object.   
     
     
         17 . The method according to  claim 16 , wherein the method is adapted for an automated additive manufacturing system. 
     
     
         18 . A non-transitory computer readable medium storing a computer program for a manufacturing assistance system for an additive manufacturing system, which, when executed by a processing element, is adapted to perform operations comprising:
 generating process data, by a process sensor unit, from measurements of one or more hardware sensors of the process sensor unit during manufacturing an object by the additive manufacturing system, wherein the process sensor unit is arranged at the additive manufacturing system and comprises one or more hardware sensors selected from a position sensor configured to measure the position of a spot of a scanner of the additive manufacturing system, a distance sensor configured to measure a position of a substrate inside a manufacturing chamber of the additive manufacturing system, a contact sensor configured to determine a contact between the substrate and a doctor blade of the additive manufacturing system, and a temperature sensor configured to measure the temperature of cooling water and/or gas inside the manufacturing chamber,   generating image data, by an imaging sensor unit, of an object during manufacturing inside the manufacturing chamber by one or more imaging sensors of the imaging sensor unit, wherein the one or more imaging sensors are arranged inside or outside of the manufacturing chamber,   generating error data, by an error detection unit, based on a human error or interference and during manufacture of the object, wherein the error detection unit is arranged inside or outside the manufacturing chamber, and sending the generated error data to an electronic control unit comprising a computing element,   collecting, by the electronic control unit, the process data generated by the process sensor unit, the image data generated by the imaging sensor unit, and the error data generated by the error detection unit,   determining, by the electronic control unit, a current state of the object by correlating the process data, the image data, and the error data to verify if the object being manufactured meets predefined requirements or has any failure, and   determining a subsequent step to be performed in the additive manufacturing system and executing the determined subsequent step during manufacturing the object.